steam trapping - an overview

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Steam trapping overview
*
s t e a m
t r a p p i n g
Make your steam system safe,
efficient and sustainable
The duty of a steam trap is to discharge condensate
while retaining live steam in the system. This ensures
your steam system is able to operate efficiently, without
the detrimental effects of unwanted condensate essential in temperature critical applications.
Condensate in the system can lead to a number of
issues such as:
- Poor heat transfer
- Damage to system and process equipment
- Poor quality or wasted product
Selecting the right steam trapping solution helps to
avoid these problems, whilst at the same time allowing
the condensate to be recovered. Information on the
significant benefits of recovering condensate can be
found at the back of this brochure.
How can Spirax Sarco help you?
We’ve been in the business of steam solutions
for over 100 years and with our exceptional team
of specialists, we take the time to understand your
needs and work with you to find the most effective steam
trapping solutions for your applications.
Our aim is to help you meet your sustainability and
efficiency goals by ensuring your steam system operates
at its optimum level at all times. Effective steam trapping
is a key factor in achieving this objective.
spiraxsarco.com
3
An introduction to steam traps
Each steam application has its own steam trap requirements. Selecting the right steam trap for your application could have
a significant, positive impact on your process, potentially improving efficiency, reducing energy costs and giving you a safer
working environment.
For example: condensate must be removed promptly from a plant where maximum heat transfer is sought at all times. The
presence of excess condensate in an item of heat transfer equipment will reduce its efficiency, preventing it from achieving its
maximum rated output and may also reduce its service life.
However; in other applications, it may be required to hold back the condensate to extract some of its heat and thus save
on steam. Furthermore, by discharging condensate well below steam temperature, flash steam losses can be reduced or
avoided altogether.
Thermodynamic steam traps
Maintaining optimum process performance
Thermodynamic steam traps are the best choice for steam mains drainage due to
their simplicity, long life and robust construction. With a large condensate capacity for their
size, the all stainless steel construction of our thermodynamic traps offer a high degree of
resistance to corrosive condensate.
Mechanical steam traps
Maintaining optimum process performance
Mechanical steam traps are ideal for use on process applications where condensate
must be removed as soon as it forms, to safeguard against temperature fluctuation
which would lead to issues such as product spoilage and inadequate heating. Our
mechanical steam trap range is adaptable to all applications where instantaneous
removal of condensate is required.
Thermostatic steam traps
Utilising heat energy in condensate
For applications where it would be desirable to make use of the heat in the condensate
such as sterilisation, a thermostatic steam trap is an ideal solution as it will not open
until the condensate temperature drops below saturated steam temperature. This
allows the heat in the condensate to be utilised before it is drained off which in turn
reduces flash steam losses and can help to reduce energy costs.
Spirax Sarco offers a complete range of steam traps to ensure you can
select the perfect trap for your application.
s t e a m
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Spirax Sarco’s steam trap range
Steam trap
operation
Thermodynamic
Thermodynamic
Mechanical
Ball float
Inverted
bucket
Thermostatic
Balanced
pressure
Bimetallic
Steam
trap
types
Main
features
• Robust design giving
excellent resistance to
waterhammer and
vibration
• High capacity
• Inexpensive
• Continuous
discharge of
condensate for
maximum heat
transfer
• Positive discharge with
tight shut-off
• Discharge condensate
close to steam
saturation temperature
Mains drainage and all
tracing applications.
Typical
applications
Size
Maximum
body rating
Maximum
operating
pressure
• Excellent air
venting capabilities
• Will not back-up with
condensate
• High capacity
• Robust design
• Near continuous
discharge of
condensate
• Minimal back-up
of condensate
• Utilises sensible heat in the condensate,
reducing flash steam losses, which saves
energy
• Excellent air venting properties for quick
start-up
Temperature /
pressure controlled
applications with
fluctuating loads
Temperature /
pressure
controlled
applications with
fluctuating loads
DN8 – DN25
(¼”– 1”)
DN15 – DN100
(½" – 4")
DN15 – DN50
(½" – 2")
DN8 – DN25
(¼"– 1")
DN8 – DN100
(¼"– 4")
PN250
PN100 and
ASME Class 600
ASME 900
PN40 and
ASME Class 300
PN420 and
ASME Class 2500
250 bar g
80 bar g
110 bar g
32 bar g
210 bar g
Some process
applications with light
loads such as small
presses and cylinders
• Where condensate back-up can be
tolerated or is required in order to remove
excess enthalpy, e.g. non-critical tracing
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Thermodynamic steam traps
How a thermodynamic steam trap works
1
2
3
4
1. On start-up, incoming pressure raises the disc and cooled
condensate, and air is immediately discharged.
2. Hot condensate flowing through the trap releases flash
steam. High velocity creates a low pressure area under the
disc and draws it towards the seat.
3. At the same time there is a pressure build-up of flash steam
in the chamber above the disc which forces it down against
the pressure of the incoming condensate until it seats on the
inner ring and closes the inlet. The disc also seats on the
outer ring and traps pressure in the chamber.
4. Pressure in the chamber is decreased by condensation of
the flash steam and the disc is raised. The cycle is then repeated.
Features and benefits:
• Positive condensate discharge with clean tight shut-off
• Discharges condensate at very close to steam temperature
that ensures maximum plant efficiency
• Just one moving part, a disc, ensures reliable operation
and minimal maintenance without having to remove from the line
• Compact and light weight, reducing installation costs
• Hardened disc and seat for long life
• One trap covers a wide range of operating pressures making
selection and replacement simple
• Insulating cover for low ambient temperature or wet environments
• Thermodynamic traps can be used on high pressure and superheated steam
and are not affected by waterhammer or vibration.
spiraxsarco.com
Thermodynamic steam traps - product range
Material
Sizes
Maximum
operating
pressure
Connection
42 bar g
Socket weld
TD42S2
TD42S2LC
Horizontal
46 bar g
Screwed
Socket weld
Flanged
TDC46M
Horizontal
10 bar g
Screwed
30 bar g
Swivel
UTD30L
UTD30H
(universal connection)
Universal
32 bar g
Flanged
TD32F
TD32FLC
Horizontal
Horizontal
Carbon steel
DN8
¼"
42 bar g
Screwed
DN20
¾"
DN25
1"
TD 259
TD52M
Recommended
installation
Horizontal
TD3-3
TD3-3
TD3-3LC
TD3-3
TD42LC
TD42L
TD52M
TD42
TD42LC
TD42H
TD42L
TD52M
TD52MLC
TD42
TD42H
TD42L
TD52M
Horizontal
Swivel
46 bar g
Screwed
Socket weld
Flanged
TDS46M
Horizontal
62 bar g
Screwed
Socket weld
Flanged
TD62M
TD62LM
Horizontal
250 bar g
Socket weld
Butt weld
Flanged
TD120M
Horizontal
Screwed
UTDS46M
TD42H
TD42L
TD52M
46 bar g
Alloy steel
Stainless
steel
(Clean
steam)
DN15
½"
TD10
Butt weld
Stainless
steel
DN10
"
BTD52L
Universal
Horizontal
10 bar g
Clamp
Tube end
BTD52L
Horizontal
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Mechanical steam traps
Ball float mechanical steam traps
Ball float (FT) mechanical steam traps have an integral air vent as standard and the options of a manually adjustable
needle valve (SLR - steam lock release mechanism) and drain cock tapping, the FT range is adaptable to all applications
where ball float traps are recommended and instantaneous removal of condensate is required.
How a ball float steam trap works
1. On start-up a thermostatic air vent allows air to bypass
the main valve (1) which would otherwise be unable to
escape (a condition known as ‘air-binding’).
1
2
3
4
2. As soon as condensate reaches the trap, the float is
raised and the lever mechanism opens the main valve.
Hot condensate closes the air vent but continues to flow
through the main valve.
3. When steam arrives the float drops and closes off the
main valve, which remains at all times below the water
level, ensuring that live steam cannot be passed.
4. As the steam condenses, the float rises allowing
condensate to be released.
Features and benefits:
• Immediate condensate discharge with clean, tight shut-off. No backup
of condensate ensures maximum plant efficiency
• Works efficiently on both heavy and light loads with no passage of
live steam
• Not affected by wide and sudden fluctuations of pressure
or flowrate
• Stainless steel internals that can tolerate corrosive
condensate
• Integral air vent to ensure rapid warm-up of plant
• Robust construction to guarantee long life against
waterhammer and vibration.
spiraxsarco.com
Ball float steam traps - product range
Material
Maximum
operating Connection DN15
½"
pressure
13 bar g
Sizes
DN20
¾"
DN25
1"
DN40
1½"
DN50
2"
DN80
3"
DN100
4"
Installation
FT43
FT43
FT53
FT43V
FT43V
FT53V
Vertical down
FT14
Horizontal
Flanged
Cast iron
14 bar g
DN32
1¼"
Screwed
FT43
Horizontal
FT14
Horizontal
FT14V
Vertical down
FT14
Horizontal
Screwed
14 bar g
Flanged
SG iron
21 bar g
Screwed
FT47
FT57
Horizontal
Flanged
FT47V
FT57V
FT47V
FT57V
Vertical down
Screwed
FTGS14
Horizontal
Flanged
FTGS14
Horizontal
14.6 bar g
17 bar g
Screwed
23 bar g
Flanged
32 bar g
Flanged
Stainless
steel
Stainless
steel
(Clean
steam)
Horizontal
FT47
FT57
Screwed
Socket weld
Carbon steel
FT14
Flanged
32 bar g
ENP coated
SG iron
cover
and
stainless
steel
body
FT14HC
FTGS14HC
Horizontal
FTC23
FTC32
Horizontal
FT450*
FTC32V
Horizontal
Vertical down
FTC32
FT44
FT54
FTC32V
FT44V
FT54V
FT44
FT54
FT44
FT54
FT44
FT450*
FT44V
FT54V
FT44V
FT54V
Vertical down
Horizontal
80 bar g
Socket weld
Flanged
FTC80
Horizontal
23 bar g
Flanged
FTS23
Horizontal
Screwed
Socket weld
Flanged
FTS14
Horizontal
19 bar g
FTS14V
Vertical down
25.5 bar g
Flanged
FT46
32 bar g
Swivel
UFT32
Universal
FTS14-4.5
Horizontal
4.5 bar ΔP
Clamp
FTS14V-4.5
Vertical down
* not PED approved
FT46
Horizontal
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Mechanical steam traps
Inverted bucket mechanical steam traps
Our inverted bucket steam traps employ a well-proven principle which relies on the difference in density between steam (a
vapour) and condensate (a liquid). They have a robust design and incorporate a simple density sensitive bucket and lever
mechanism.
How an inverted bucket steam trap works
1
2
3
4
1. As condensate reaches the trap it forms a waterseal
inside the body. The weight of the bucket keeps the valve
off its seat. Condensate can then flow around the bottom
of the bucket and out of the trap.
2. When steam enters the underside of the bucket it gives
it buoyancy and the bucket rises. This positions the lever
mechanism such that the main valve ‘snaps’ shut due to
flow forces.
3. The bucket will lose its buoyancy as the enclosed
steam condenses due to radiation losses and steam
escapes through the vent hole. Once this happens the
weight of the bucket will pull the valve off its seat and the
cycle is then repeated.
4. Any air reaching the trap will also give the bucket buoyancy and close the valve preventing condensate flow. The
small vent hole positioned at the top of the bucket will lead air into the top of the trap. Because the vent hole at the top of
the bucket is small in diameter it will vent air very slowly. Where the venting of air may be a particular problem, this can
be overcome simply by fitting an external air vent in parallel.
Features and benefits:
• Near continuous condensate discharge with tight shut-off. Minimal
back-up of condensate ensures maximum plant efficiency
• Deep water-seal to protect against the possibility of steam loss
• Suitable for superheat conditions when fitted with internal inlet check valve
• Simple and robust construction to guarantee long life against
waterhammer and vibration
• Stainless steel internals are attached to the cover for ease of maintenance
• Integral strainer (HM, HM34 and SCA models only)
• Optional blowdown valve (only for HM and HM34).
spiraxsarco.com
Inverted bucket steam traps - product range
Material
Cast iron
Carbon
steel
Sizes
Maximum
operating
pressure
Connection
13 bar g
Screwed
Flanged
14 bar g
Screwed
Flanged
22 bar g
Screwed
Flanged
32 bar g
Screwed
Socket weld
Flanged
HM34
Horizontal
41 bar g
Screwed
Socket weld
Flanged
SCA
Horizontal
116 bar g
Screwed
Socket weld
Flanged
DN15
½"
DN20
¾"
DN25
1"
DN40
1½"
S
SF
DN50
2"
DN80
3"
Installation
Horizontal
HM
Horizontal
200
IBV Series C
IBV Series C-LDF2
Vertical
Vertical
Screwed
Socket weld
Flanged
SIB30
SIB30H
Horizontal
Swivel
UIB30
UIB30H
Universal
60 bar g
Screwed
Flanged
SIB45
Horizontal
63 bar g
Swivel
UIB46
Universal
123 bar g
Screwed
Socket weld
Flanged
30 bar g
Stainless
steel
Alloy steel
IBV Series Z
Vertical
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Thermostatic steam traps
1
How a balanced pressure thermostatic steam trap works
1. On start-up, cold air and condensate enter the trap. As the capsule is also cold, the valve
is open and the air and condensate are discharged.
2. The capsule warms up as the condensate approaches steam temperature. Its liquid
filling boils, and the resultant vapour pressure acting on the diaphragm pushes the valve
head towards the seat, fully closing at the selected discharge
temperature before any steam is lost.
2
3. As the condensate within the trap cools, the vapour filling
condenses and the internal capsule pressure falls. The valve
reopens, discharges condensate and the cycle repeats.
Features and benefits:
• Condensate is discharged at below steam saturation temperature, utilising sensible heat in the
condensate and reducing flash steam losses
• Automatically discharges air and other incondensable gases to aid rapid warm-up of plant
• It automatically adjusts itself to variations of steam pressure up to its maximum
operating pressure and can tolerate superheat up to 70°C
• Discharge temperature set by capsule selection – no requirement to adjust on site
• Manufactured using advanced technology
to exacting quality standards
• All stainless steel internals extend working life
and reduce plant maintenance
• The BPC32 and BPS32 series has a two bolt
cover design for ease of maintenance.
3
spiraxsarco.com
Balanced pressure thermostatic steam traps - product range
Material
Brass
Maximum
operating
pressure
13 bar g
Sizes
Connection
DN8
¼"
DN10
"
DN15
½"
DN20
¾"
DN25
1"
DN40
1½"
Recommended
installation
BPT13S
BPT13US
Horizontal
BPT13A
BPT13UA
Angle
Screwed
Screwed
BPM21L
Horizontal
21 bar g
Socket weld
Carbon
steel
BPM21L
Screwed
Socket weld
BPC32
BPC32Y
Horizontal
Flanged
BPC32
BPC32F
BPC32Y
BPC32YF
Horizontal
32 bar g
Screwed
21 bar g
Stainless
steel
30 bar g
32 bar g
7 bar g
MST21
MST21H
TSS21
MST21H
BPW32
Screwed
Socket weld
Flanged
SBP30
Vertical down
Vertical down
Horizontal
Screwed
Socket weld
Flanged
BPS32
BPS32Y
Horizontal
Swivel
UBP32
Universal
BTM7
BTS7
Vertical down
BTM7
BTS7
BTS7.1
Vertical down
BTM7
BTS7
Clamp
Tube end
6 bar g
MST21
Sandwich
between
flanges
Screwed
Stainless
steel
(Clean
steam)
Horizontal
Clamp
Tube end
BTM7
BTS7
Vertical down
BT6-BH
BT6-BL
Vertical down
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Thermostatic steam traps
1
How a bimetallic thermostatic steam trap works
1. On start-up, the bimetallic element is relaxed and the valve is open. Cooled condensate,
plus air, is immediately discharged.
2. Hot condensate flowing through the trap heats the bimetallic element causing it to pull
the valve towards the seat.
3. As the hot condensate is discharged and approaches steam
saturation temperature the bimetallic element closes the valve.
When there is no flow through the trap the condensate
surrounding the element cools causing it to relax and the
upstream pressure opens the valve. Condensate is discharged
and the cycle repeats.
Features and benefits:
• Condensate is discharged at below steam saturation temperature,
utilising sensible heat in the condensate and reducing flash steam losses
• Automatically discharges air and other incondensable gases to aid
rapid warm-up of plant
• The bimetal elements can work over a wide range of steam pressures
without any need for on-site adjustment
• Resistant to waterhammer and freezing
• The SMC32 series has a two bolt cover design for ease.
2
3
spiraxsarco.com
Bimetallic thermostatic steam traps - product range
Material
Sizes
Maximum
operating
pressure
Connection
21 bar g
Socket weld
Butt weld
Flanged
DN8
¼"
DN10
"
DN20 DN25
¾"
1"
DN40
1½"
DN50 DN80
2"
3"
DN100
4"
SP80
SP100
Recommended
installation
Horizontal
Screwed
Socket weld
Butt weld
SMC32
SMC32Y
Horizontal
Flanged
SMC32
SMC32F
SMC32Y
SMC32YF
Horizontal
32 bar g
Carbon
steel
DN15
½"
40 bar g
Screwed
Socket weld
Flanged
45 bar g
Screwed
Socket weld
Butt weld
Flanged
17 bar g
Screwed
21 bar g
Swivel
USM21
Universal
Swivel
USM32
Universal
Screwed
Socket weld
Flanged
PBX
Horizontal
ABL
HP45
T3
Horizontal
Horizontal
Vertical down
Stainless
steel
32 bar g
45 bar g
Screwed
Socket weld
Butt weld
Flanged
80 bar g
Alloy steel
100 bar g
150 bar g
210 bar g
Socket weld
Butt weld
Flanged
SM45
Horizontal
HP80
Horizontal
HP100
Horizontal
HP150
Horizontal
HP210
Horizontal
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Reducing production running costs
Spirax Sarco can supply fabricated steam trap stations
and a range of ‘quick-fit’ solutions that will allow rapid
steam trap replacement and significantly reduce
labour costs.
Universal steam traps for use with pipeline
UTD30L and UTD30H
up to 30 bar g
UTDS46M
up to 46 bar g*
Thermodynamic
steam trap
Thermodynamic
steam trap
Pipeline connectors
Key features:
• A simple two-bolt connector
design allows quick and simple
maintenance of a steam trap Reducing system downtime and
maintenance costs compared to
traditional trapping stations
• Single permanent in-line
component for ease of
specification and installation
• Prefabricated construction
minimises on-site fabrication
and the welded joints eliminate
potential leak paths
• All stainless steel construction
for maximum system life.
PC10HP
up to 62 bar g*
PC20
up to 32 bar g
PC30 series
up to 62 bar g*
spiraxsarco.com
connectors for a ‘quick fit’.
UFT32
up to 32 bar g
UIB30 / UIB30H up to 30 bar g
UBP32
up to 32 bar g
USM21
up to 21 bar g
Ball float
steam trap
UIB45
up to 63 bar g*
Balanced pressure
steam trap
USM32
up to 32 bar g
Inverted bucket
steam trap
Bimetallic steam trap
The pipeline connectors require 2 bolts for
connection with a steam trap.
*subject to limitation of pipeline connector
Steam trapping station
PC3000 series
up to 62 bar g*
PC40 series
up to 62 bar g*
PC4000 series
up to 62 bar g*
STS17.2
up to 17.5 bar g
Steam trapping station
Downstream
isolation valve
Upstream
isolation valve
Check
valve
Pipeline connector with
an integral strainer screen
* Subject to pressure limits of trap selected
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Steam tracing using our
compact dual duty manifold
Key features:
• Minimises on-site fabrication and testing
Steam tracing is used principally to maintain a reasonable
product temperature and viscosity in order to simplify
• Lower cost than conventional welded design
pumping, avoid freezing, solidification and stagnation.
• Shortens project lead times
Although the rates of condensate are relatively small, trap
• Space saving with standardised design
populations will be large since all tracer lines should be
individually trapped. For ease of design and layout, the
• Lightweight to support and easy to install with
optional mounting kit
condensate from the traps is collected in a manifold. The
steam to the tracers can be distributed utilising a similar
• Easy to maintain
manifold arrangement.
• Optional insulation jacket for energy conservation.
Our forged MSC series manifold minimises on-site
fabrication and testing.
DN
Tracer connections
Manifold type
Number
of tracer
connections
15
20
BSP
NPT
SW
MSC04
4
●
●
●
●
●
MSC08
8
●
●
●
●
MSC12
12
●
●
●
●
EN 10204 3.1.B
certification
Options
Insulation
jacket
Mounting
kit
Standard
●
●
●
Standard
●
●
●
Standard
●
●
Steam main
Condensate main
Product line
To tracer lines
From tracer lines
MSC steam
distribution manifold
MSC condensate
collection manifold
We will advise on the
best steam trap type for
your requirements
Typical applications for steam traps
Mains drainage
Vulcaniser application
Condensate main
Steam main
Steam
to jacket
Steam
into
chamber
Condensate
from jacket
to condensate
system
Condensate
from chamber
to waste
Hot plate process
Hotplates
Steam in
Condensate out
Condensate in
19
spiraxsarco.com
Turbine drainage
Process equipment
Steam in
Steam out
Condensate
out
Air vent
Condensate
Drainage of a separator
Secondary flow
Steam
Condensate
Condensate
spiraxsarco.com
The benefits of effective steam trapping
Spirax Sarco are focused on helping our customers achieve process efficiency, increased production output and
energy savings, and we know the importance of effective steam trap management in achieving this. A healthy
steam trap population allows condensate to be removed from the steam system effectively which means it can be
re-used. We call this ‘condensate recovery’ and it saves energy and cost in a number of different ways:
Reduced fuel costs
Normally, condensate will contain around 25% of the usable energy of the steam from which it came. Returning
this to the boiler feedtank can save thousands of pounds per year in energy alone.
Energy saving
Condensate returned to the feedtank reduces the need for boiler blowdown, which is used to reduce the
concentration of dissolved solids in the boiler. This therefore reduces the energy lost from the boiler during the
blowdown process.
Reduced water charges
Returning and re-using condensate reduces the requirement for fresh replacement water.
Reduced chemical treatment costs
Re-using as much condensate as possible minimises the need for costly chemicals to treat raw water.
Reduced effluent costs
In many countries there are restrictions on releasing effluent at elevated temperatures so it must be cooled if
discharged which incurs extra costs.
Spirax Sarco are always on hand to advise you about the best ways to manage your steam system and to help
ensure you continue to reap these benefits.
For more information about our
steam trapping solutions, or any
of our other solutions and services
please visit spiraxsarco.com.
spiraxsarco.com
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* Manufacturing sites
Spirax-Sarco Limited, Charlton House, Cheltenham,
Gloucestershire, GL53 8ER, UK
T +44 (0)1242 521361
F +44 (0)1242 573342
E enquiries@uk.spiraxsarco.com
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